Assembly
WARNING:Fire Hazard
Do not smoke or carry lighted tobacco or an open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury
CAUTION:
Cleaning Aluminum Surfaces
Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminum sealing surfaces.
NOTE:
During assembly, all bearing surfaces must be lubricated before assembly or installation.
The crankshaft main bearings and connecting rod bearings are precision selective fit. Check bearing clearances.
1. Install the (A) upper crankshaft main bearings and the (B) crankshaft thrust main bearing.
2. Install the crankshaft.
NOTE: The crankshaft main bearing caps are numbered 1 to 5 with No. 1 at the front of the engine. Make sure the arrow faces the front of the engine.
NOTE: Apply axial load to the rear of the crankshaft simultaneously to tightening of the bolts.
3. Install the five lower crankshaft main bearings and the five main bearing caps. Tighten cap bolts evenly to 90-108 Nm (66-80 ft. lbs.).
4. Install the piston and connecting rod assemblies. Install the four connecting rod caps. Use Removal and Installation procedure. Service and Repair
NOTE: Coat the rear oil seal area and the crankshaft rear oil seal lip with light engine oil.
5. Ensure the crankshaft rear oil seal is on correctly and that the edges are not rolled over.
6. Use Crankshaft Real Seal Pilot T88P-6701-B2 and Crankshaft Rear Seal Replacer T88P-6701-B1 to install the crankshaft rear oil seal.
7. Install a new crankshaft rear oil seal retainer gasket (6344) and install the crankshaft rear seal retainer. Tighten the bolts to 20-30 Nm (15-22 ft. lbs.).
8. Install the oil pump.
9. Install the oil baffle and tighten the bolts to 20-30 Nm (15-22 ft. lbs.).
10. Install the oil pump screen and cover assembly and tighten the bolts to 8-11.5 Nm (71-102 inch lbs.).
11. Clean and inspect the mounting faces of both the oil pan and the cylinder block. To remove all traces of previous sealer, use solvent to clean the cylinder block and oil pump. Both surfaces must be flat, clean, and dry.
NOTE: Install the oil pan within ten minutes after the sealer is applied.
12. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A5 approximately 3.0 mm (1/8 in) wide at the oil pump to cylinder block joints and the crankshaft rear oil seal retainer to cylinder block joints.
NOTE: Ensure the press fit tabs are fully engaged in the oil pan gasket channel when installing the oil pan gasket and oil pan.
13. Install the oil pan gasket in the oil pan.
14. Install the oil pan. Tighten the bolts in the sequence shown to 20-30 Nm (15-22 ft. lbs.).
CAUTION: Always use new cylinder head bolts.
NOTE: Lubricate the cylinder head bolts with engine oil prior to installation.
15. Install the cylinder head assembly and torque the cylinder head bolts in the following sequence.
A) Torque all the bolts in sequence to 40-60 Nm (30-44 ft. lbs.).
B) Back the bolts off 1/2 turn (180°).
C) Retorque all the bolts in sequence to 40-60 Nm (30-44 ft. lbs.).
D) Rotate all the bolts, in sequence, an additional 180° in two steps of 90° each.
16. Install the valve cover.
17. Install the engine mounting bracket and tighten to 41-57 Nm (30-42 ft. lbs.).
18. Install the front engine accessory drive bracket and tighten bolts to 40-55 Nm (29.5-40.5 ft. lbs.).
19. Install the power steering pump and tighten bolts to 20-30 Nm (15-22 ft. lbs.).
20. Use Strap Wrench D85L-6000-A or equivalent and install the power steering pump pulley. Tighten bolts to 20-30 Nm (15-22 ft. lbs.).
21. Install the timing belt guide and the crankshaft sprocket.
22. Install the inner engine front cover.
23. Install the water pump. Refer to Cooling System.
24. Install the camshaft sprocket and tighten bolt to 95-115 Nm (70-85 ft. lbs.).
25. Install the timing belt tensioner and timing belt.
26. Roll the engine over two times and recheck the timing marks.
27. Install the outer engine front cover and tighten bolts to 8-11.5 Nm 971-101 inch lbs.).
28. Install the crankshaft position (CKP) sensor and tighten bolts to 5-7 Nm (40-61 inch lbs.).
29. Use Strap Wrench D85L-6000-A or equivalent and install the crankshaft pulley and tighten bolt to 110-130 Nm (81-96 ft. lbs.).
30. Install the crankcase vent oil separator.
31. Install the four spark plugs. Refer to Powertrain Management.
32. Install a new gasket and the water outlet connection and tighten bolts to 10-16 Nm (8-12 ft. lbs.).
33. Install the ignition coil mounting bracket assembly and tighten the bolts to 8-11.5 Nm (70-101 inch lbs.).
34. Install the radio ignition interference capacitor and the ignition coil.
NOTE: Torque the bolts evenly and sequentially.
35. Install a new gasket and the exhaust manifold. Tighten nuts to 20-24 Nm (14.7-17.7 ft. lbs.).
36. Install the generator. Tighten upper bolt to 40-55 Nm (29-40 ft. lbs.). Tighten lower bolt to 20-30 Nm (15-22 ft. lbs.).
37. Install the oil pressure switch and tighten to 11-16.5 Nm (8-12 ft. lbs.).
38. Install the oil filter.
39. Install the spark plug wires. Refer to Powertrain Management.
40. Install the intake manifold runner control (IMRC) and the intake manifold.
41. Install the fuel charging wiring harness.
42. Connect the following electrical connectors:
^ Water temperature indicator sender unit.
^ Temperature gauge.
^ Radio interference capacitor.
^ Ignition coil.
^ IMRC.
43. Connect the (A) idle air control (IAC) valve and the (B) throttle position (TP) sensor electrical connectors.
44. Connect the four fuel injector electrical connectors.
45. Connect the CKP sensor electrical connector.
46. Install the oil level indicator tube and tighten the bolt to 8-11.5 Nm (70-101 inch lbs.).
48. Install a new gasket and connect the EGR tube to the exhaust manifold and finger tighten nuts.
48. Install a new gasket and install the EGR tube to the EGR valve and tighten to 20-28 Nm (14.7-20.5 ft. lbs.).
47. Tighten the EGR tube to the exhaust manifold nuts to 5-7 Nm (44.6-62 inch lbs.).